Single Trip Multi-Zone Completion System for Efficient Wellbore Treatment
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Solution Overview
Problem
Deep well drilling operations face challenges due to the time-consuming and costly process of assembling and deploying service tools over long distances, leading to increased costs and risks of tool loss, as well as restricted tool sizes due to wellbore diameter reduction with each trip, necessitating more efficient multi-zone completion systems.
Innovation Solution
A single trip multi-zone completion system that includes an outer completion string with sand screens and a flow control device, along with an insert string equipped with control and data acquisition modules and mechanical coupling mechanisms, allowing for simultaneous gravel packing and fracturing of multiple zones and intelligent regulation of hydrocarbon production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-zone completion operations are performed with multiple trips into the wellbore, then each zone can be treated individually with dedicated tools, but the operation time and cost increase significantly, and the wellbore inner diameter is reduced with each trip
Solution Approach 1:
The patent combines multiple treatment operations for different zones into a single trip multi-zone completion system. The system integrates multiple flow control devices, sand screens, and treatment tools that can simultaneously treat multiple pay zones during one deployment, eliminating the need for separate trips for each zone treatment and significantly reducing operation time and cost
Solution Approach 2:
The completion system is designed with multi-functional components that can perform various operations including fracturing, gravel packing, and production control across multiple zones. The flow control devices and treatment tools are configured to handle different treatment requirements for different zones within a single deployed system, providing universal functionality without requiring multiple specialized trips
2Ease of operation
If multiple trips are made into the wellbore for service operations, then tools can be deployed and adjusted, but the inner diameter of the wellbore is reduced with each trip, restricting tool size
Solution Approach 1:
The system is pre-configured with all necessary flow control devices, sand screens, and treatment tools before being deployed into the wellbore in a single trip. The modular components are assembled and positioned in advance, allowing the entire multi-zone treatment system to be installed without requiring subsequent trips that would further reduce wellbore diameter and restrict tool size
3Productivity
If a single trip multi-zone system is deployed to reduce operation time and cost, then efficiency improves, but the system complexity increases
Solution Approach 1:
The multi-zone completion system is divided into modular segments, with each zone having its own flow control device and treatment components. This segmentation allows the complex system to be broken down into manageable modules that can be independently configured, installed, and controlled, reducing the operational complexity despite the integrated design
Solution Approach 2:
The system employs a nested configuration where flow control devices and treatment tools are positioned within the completion string in a hierarchical arrangement. Each zone's components are nested within the overall system structure, allowing compact integration of multiple functions while maintaining organized control over each zone's treatment and production
4Ease of operation
If flow control devices are integrated into sand screens for multi-zone treatment, then production regulation is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The flow control devices are integrated as intermediary components within the sand screen structure, serving as mediators between the formation and the production string. This integration allows production regulation to be achieved through a unified component design that combines filtration and flow control functions, simplifying the overall system despite the enhanced functionality
Data Source
Figure 1~2
AI summary
A single trip multi-zone completion system for producing from one or more formation zones, comprising an outer completion string having at least one sand screen arranged thereabout adjacent the one or more formation zones; a flow control device disposed within the at least one sand screen and movable between an open position and a closed position, wherein, when in the open position, fluids may communicate from the one or more formation zones, through the at least one sand screen, and into the outer completion string; an insert string arranged within the outer completion string and being communicably coupled to the outer completion string at a crossover coupling, the crossover coupling having one or more control lines coupled thereto; and at least one control and data acquisition module disposed on the insert string and having one or more coupling mechanisms.